Assistant System Engineer Jobs in DeKalb, IL (NOW HIRING)

Composites Application Engineer

Position Summary
We are seeking an innovative and technically driven Composites Application Engineer to support the development, optimization, and implementation of advanced composite and additive manufacturing processes. This role is responsible for process development and product support related to Automated Fiber Placement (AFP), Automated Tape Laying (ATL), large-format additive manufacturing, metal 3D printing, automated inspection systems, and related advanced manufacturing technologies.

The ideal candidate will work cross-functionally with engineering, manufacturing, and customer teams to develop optimized production processes, support machine qualifications, assist with software development initiatives, and provide technical expertise throughout the full project lifecycle. This position requires strong analytical capabilities, customer-facing communication skills, and the ability to support domestic and international projects in fast-paced industrial environments.

Employment Type: Full-Time | Salaried

Key Responsibilities
• Review and analyze customer manufacturing requirements for composite and additive manufacturing applications
• Develop, optimize, and validate manufacturing processes for advanced composite and automated production systems
• Research and evaluate alternative manufacturing methods and emerging technologies
• Support Automated Fiber Placement (AFP), Automated Tape Laying (ATL), additive manufacturing, and automated inspection applications
• Assist in machine qualification activities and production readiness validation
• Support projects from proposal development through installation, commissioning, and production ramp-up
• Generate technical documentation, process reports, and customer-facing engineering deliverables
• Provide technical training to internal personnel and customers on equipment operation, process optimization, and manufacturing best practices
• Support composite software development initiatives and process integration activities
• Travel to customer and partner facilities to support implementation, troubleshoot production challenges, and resolve process-related issues under tight timelines
• Collaborate with multidisciplinary engineering and manufacturing teams to improve product performance and operational efficiency
• Maintain regular and reliable attendance at the Rockford, IL facility
• Work overtime or off-shift hours as required to support project and customer needs

Required Qualifications
• Bachelor's degree in Mechanical Engineering, Materials Science, Aerospace Engineering, Industrial Engineering, or related technical discipline
• Experience with CAD software such as CATIA, SolidWorks, Pro/E, or similar platforms
• Proficiency with Microsoft Office applications including Word, Excel, Outlook, and PowerPoint
• Strong verbal, written, and interpersonal communication skills
• Professional demeanor with the ability to work directly with customers and internal stakeholders
• Willingness and ability to travel domestically and internationally

Preferred Qualifications
• Working knowledge of Python or other programming languages
• Experience with NC programming and the ability to read and interpret NC files
• Experience with large-scale additive manufacturing, composite layup processes, 3D printing, AFP, or ATL technologies
• Experience programming and operating CNC machine tools and robotic manufacturing platforms
• Familiarity with industrial robotics and machine vision systems
• Understanding of advanced manufacturing process development and automation technologies
• Experience supporting aerospace, industrial manufacturing, or high-performance production environments preferred

Location & Travel Requirements
• Rockford, IL
• Domestic and international travel required based on customer and project demands

Compensation & Benefits
• Salary Range: $80,000 – $130,000 annually, based on experience and qualifications
• Comprehensive benefits package available
• Opportunity to support cutting-edge composite and additive manufacturing technologies in a highly innovative engineering environment

About Lean Synergy
Lean Synergy Solutions is a Veteran-owned and operated recruiting firm specializing in aligning top-tier talent with high-impact opportunities across diverse industries. Our team of military veterans and industry professionals brings a mission-driven approach to workforce solutions, helping organizations secure skilled professionals who drive operational success. We are committed to supporting transitioning service members, veterans, military spouses, and civilian professionals by connecting them with meaningful, long-term career opportunities across government, public, and private sector organizations.